The “Impossible” Tech Behind SpaceX’s New Engine

February 13, 2019 by Tom Nardi 92 Comments

Followers of the Church of Elon will no doubt already be aware of SpaceX’s latest technical triumph: the test firing of the first full-scale Raptor engine. Of course, it was hardly a secret. As he often does, Elon has been “leaking” behind the scenes information, pictures, and even video of the event on his Twitter account. Combined with the relative transparency of SpaceX to begin with, this gives us an exceptionally clear look at how literal rocket science is performed at the Hawthorne, California based company.

This openness has been a key part of SpaceX’s popularity on the Internet (that, and the big rockets), but its been especially illuminating in regards to the Raptor. The technology behind this next generation engine, known as “full-flow staged combustion” has for decades been considered all but impossible by the traditional aerospace players. Despite extensive research into the technology by the Soviet Union and the United States, no engine utilizing this complex combustion system has even been flown. Yet, just six years after Elon announced SpaceX was designing the Raptor, they’ve completed their first flight-ready engine.

The full-flow staged combustion engine is often considered the “Holy Grail” of rocketry, as it promises to extract the most possible energy from its liquid propellants. In a field where every ounce is important, being able to squeeze even a few percent more thrust out of the vehicle is worth fighting for. Especially if, like SpaceX, you’re planning on putting these new full-flow engines into the world’s largest operational booster rocket and spacecraft.

But what makes full-flow staged combustion more efficient, and why has it been so difficult to build an engine that utilizes it? To understand that, we’ll need to first take a closer look at more traditional rocket engines, and the design paradigms which have defined them since the very beginning.

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A Network Attached Radiation Monitor

February 13, 2019 by Tom Nardi 25 Comments

It started as a joke, as sometimes these things do. [Marek Więcek] thought building a personal radiation detector would not only give him something to work on, but it would be like having a gadget out of the Fallout games. He would check the data from time to time and have a bit of a laugh. But then things got real. When he started seeing rumors on social media that a nearby nuclear reactor had suffered some kind of radiation leak, his “joke” radiation detector suddenly became serious business.

With the realization that having his own source of detailed environmental data might not be such a bad idea after all, [Marek] has developed a more refined version of his original detector (Google Translate). This small device includes a Geiger counter as well as sensors for more mundane data points such as temperature and barometric pressure. Since it’s intended to be a stationary monitoring device, he even designed it to be directly plugged into an Ethernet network so that it can be polled over TCP/IP.

[Marek] based the design around a Soviet-era STS-5 Geiger tube, and outfitted his board with the high voltage electronics to provide it with the required 400 volts. Temperature, barometric pressure, and humidity are read with the popular Bosch BME280 sensor. If there’s no Ethernet network available, data from the sensors can be stored on either the built-in SPI flash chip or a standard USB flash drive.

The monitor is powered by a PIC32MX270F256B microcontroller with an Ethernet interface provided by the ENC28J60 chip. In practice, [Marek] has a central Raspberry Pi that’s polling the monitors over the network and collecting their data and putting it into a web-based dashboard. He’s happy with this setup, but mentions he has plans to add an LCD display to the board so the values can be read directly off of the device. He also says that a future version might add WiFi for easier deployment in remote areas.

Over the years we’ve seen a fair number of radiation monitors, from solar-powered WiFi-connected units to the incredible work [Radu Motisan] has done building his global network of radiation detectors. It seems hackers would rather not take somebody else’s word for it when it comes to the dangers of radiation.

Get Organized With This Raspberry Pi E-Ink Calendar

February 11, 2019 by Tom Nardi 15 Comments

Like many hackers, we love e-ink. There’s something mesmerizing and decidedly futuristic about the way the images shift around and reconstitute themselves. Like something from Harry Potter, but that you can buy on Alibaba instead of from a shop in Diagon Alley. But as anyone who’s used the technology can tell you, the low refresh rate of an e-ink screen limits its potential applications. It works great for reading books, but beyond that its struggled to find its niche in a world of cheap LCDs.

But [Zonglin Li] has recently wrapped up a project which shows that e-ink has at least one more use case: personal calendars. You can get way with only updating the screen once a day so the refresh rate won’t matter, and the rest of the time it’s going to be static anyway so you might as well enjoy the energy savings of leaving the screen off. With a Raspberry Pi behind the scenes pulling data from the Internet, it can populate the calendar with everything from your personal schedule to when your favorite podcast drops.

In practice, [Zonglin] is actually updating the display every hour as he’s included the current weather conditions on the top left of the screen, but even still, this is a perfect application for the very unique properties of e-ink displays. The display is a 7.5 inch 640×384 model from Waveshare that retails for about $50 USD, so between the display, the Raspberry Pi, and something to put it all in (here, a picture frame) this is a pretty cheap build compared to some of the large format e-ink displays out there.

The software side is written in Python 3, and [Zonglin] has documented how others can easily plug in their own information so it can pull schedule data from Google Calendar and local conditions from Open Weather Map. The MIT licensed source code is also very well organized and commented, so this could serve as an excellent base if you’re looking to create a more comprehensive e-ink home information display.

If this seems a little too pedestrian for your tastes, you could always put together an e-ink movie player, a surprisingly functional Linux terminal, or a very slick ESP8266-based name tag. If you’ve got the better part of $1K USD and don’t know what to do with it, you could even get an e-ink license plate.

This 3D Printed LED Softbox Really Shines

February 10, 2019 by Tom Nardi 8 Comments

Generally speaking, objects made on desktop 3D printers are pretty small. This is of course no surprise, as filament based printers are fairly slow and most don’t have very large beds to begin with. Most people don’t want to wait days for their project to complete, so they use 3D printed parts where it makes sense and supplement them with more traditional components such as aluminum extrusion wherever possible. But not always…

This 3D printed photography softbox created by [Nicholas Sherlock] doesn’t take the easy way out for anything. With the exception of the LEDs and the electronics to drive them, everything in the design has been printed on his Prusa i3. It wasn’t the easiest or fastest way to do it, but it’s hard to argue with the end result. Perhaps even more impressive than the final product is what it took to get there: he actually had to develop a completely new style of part infill he’s calling “Scattered Rectilinear” to pull it off.

Overall the design of the light itself isn’t that complex, ultimately it’s just a box with some LEDs mounted at the back and a pretty simple circuit to control their intensity. The critics will say he could have just used a cardboard box, or maybe wood if he wanted something a little bit stronger. But the point of this project was never the box itself, or the LEDs inside it. It’s all about the diffuser.

[Nicholas] forked Prusa’s version of Slic3r to add in his “Scattered Rectilinear” infill pattern, which is specifically designed to avoid the standard “ribs” inside of a 3D printed object. This is accomplished with randomized straight infill passes, rather than the traditionally overlapped ones. The inside of the print looks very reminiscent of fiberglass mat, which is perhaps the best way to conceptualize its construction. In terms of the final part strength, this infill is abysmal. But on the plus side, the light from the LEDs passing through it emerges with a soft pleasing look that completely obscures the individual points of light.

Anyone with a big enough 3D printer can run off their own copy of his light, as [Nicholas] has released not only his forked version of Slic3r but all of the STL files for the individual components. He’s also put together an exceptionally well documented Thingiverse page that has instructions and detailed build photos, something that’s unfortunately very rare for that platform.

If you’re in the market for a DIY softbox and don’t have a 3D printer handy, fear not. We’ve covered a few that you can build with more traditional methods, as well as several tips and tricks which you can use to get the most out of your photos and videos.

A Tiny IDE For Your ATtiny

February 8, 2019 by Tom Nardi 23 Comments

When writing code for the ATtiny family of microcontrollers such as a the ATtiny85 or ATtiny10, people usually use one of two methods: they either add support for the chip in the Arduino IDE, or they crack open their text editor of choice and do everything manually. Plus of course there are the stragglers out there using Eclipse. But [Wayne Holder] thinks there’s a better way.

The project started out as a simple way for [Wayne] to program the ATtiny10 in C under Mac OS, but has since evolved into an open source, cross-platform integrated development environment (IDE) for programming a wide range of ATtiny chips in C, C++, or Assembly. Not only does it integrate the source code editor and programmer, but it even bundles in documentation for common variants of the chips including block diagrams and pinouts; making it a true one-stop-shop for ATtiny hacking.

His IDE runs under Java, including OpenJDK, and [Wayne] provides a stable pre-built executable for those who don’t want to clone the whole GitHub repository. He’s included the GNU/AVR toolchains, though notes that testing so far has been limited to Mac OS, and he’s interested in feedback from Windows and Linux users. Assembly is done either with GNU AVR-AS, or an assembler of his own design, though the latter is currently limited to the ATTiny10.

To actually get the code onto the chip, the IDE supports using the Arduino as a programmer as well as dedicated hardware like the BusPirate or the USBasp. If you go the Arduino route, [Wayne] has even come up with a little adapter board which he’s made available through OSH Park to help wrangle the diminutive chips.

The ATtiny10 might have something of a learning curve, but in exchange this family of tiny microcontrollers offers an incredible amount of capability. When you’re working with what’s essentially a programmable grain of rice, the only limit is your own creativity.

A Crash Course In 3D Printed Venturi Pumps

February 8, 2019 by Tom Nardi 15 Comments

Venturi pumps, commonly referred to as aspirators, are a fantastic way of moving around things which you might not want spinning around inside of a pump, and one of the easiest ways to create a vacuum. According to his research, [Tuval Ben Dosa] believed such a device would be a good way to move corrosive gasses which would normally eat up a blower fan; all he had to do was figure out how to 3D print one to his specifications.

Put simply: if you take a “T” shaped pipe and pass a fluid (such as air or water) through the straight section, a vacuum will be created on the shorter side due to the Venturi effect. As long as you don’t mind the substance you wish to pump getting mixed into your working fluid, it’s a simple way to bring something “along for the ride” as the fluid makes its way through the pipe.

[Tuval] needed a way to remove the chlorine gasses produced by his PCB etching station, and an aspirator seemed like the perfect solution. He just needed to pump clean air through a Venturi, which would suck up the chlorine gas on the way through, and ultimately carry it outside. But he soon found that while a pump based on the Venturi effect is simple conceptually, getting it to work in the real world is a bit trickier. Especially when you’re dealing with something like 3D printing, which brings in its own unique challenges.

He tried modeling a few designs he found online in 3D and printing them out, but none of them worked as expected. The most common problem was simply that no vacuum was being generated, air was freely moving out of both sides. While [Tuval] doesn’t claim to have any great knowledge of fluid dynamics, he reasoned that the issue was due to the fact that most Venturi pumps seem designed to move water rather than air. So he designed a new version of the pump which had a more pronounced nozzle on the inlet surrounded by a cavity in which the gases could mix.

His modified design worked, and now anyone with a 3D printer can run off their own Venturi device for quickly and easily giving potentially harmful fumes or gases the boot. If this is one of those things you’d feel more comfortable buying than building, don’t worry, we’ve previously covered using a low-cost aspirator as a vacuum source in the home lab.

The Blackest Black, Now In Handy Pocket Size

February 8, 2019 by Tom Nardi 24 Comments

If you thought “carbon nanotubes” were just some near-future unobtainium used in space elevators, don’t worry, you certainly aren’t alone. In reality, while the technology still has a way to go, carbon nanotube production has already exceeded several thousand tons per year and there are products you can buy today that are using this decidedly futuristic wonder material. Now there’s even one you can put in your pocket.

Created by [Simon], a designer in the UK, this small carbon nanotube array is described as “A simulated black hole” because the surface absorbs 99.9% of the visible light that hits it. Protected by a clear acrylic case, the sample of the material makes a circle that’s so black it gives the impression you’re looking into deep space. Unfortunately, no time-dilating gravitational forces are included at any of level of support in the ongoing Kickstarter campaign; but considering it was 100% funded in just a few hours, it seems like most people are OK with the trade-off.

[Simon] is well aware of the ongoing war between different methods of creating the “Blackest Black”, and he thinks he’s put his money (and by extension, his backer’s) money on the winner. Singularity is using a similar technology to the exclusively-licensed Vantablack, rather than a super-dark paint like “Black 3.0”. In fact he’s so confident that Singularity will appear darker than Black 3.0 that he mentions a head-to-head comparison is currently in the works.

If there’s a downside to the carbon nanotube array used in Singularity, it’s that you can’t actually touch it. [Simon] warns that while the acrylic case is only held together with magnets and can be opened for more careful inspection, actually touching the surface is absolutely not recommended. He says that even dust getting on the material is going to adversely effect its ability to absorb light, so you should really keep it buttoned up as much as possible.

While the Singularity looks like an interesting way to experience near perfect blackness, the concept itself is far from a novelty. A material that can absorb essentially all the light that hits it has important scientific, military, and of course artistic applications; so figuring out how to pull it off has become a pretty big deal.